GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Fuel Junction Block Replacement

Removal Procedure

    Object Number: 310799 Size: SH
  1. Move the hood to the service position, by moving the hood hinge bolts (1) to the service position (2).
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 813243 Size: SH
  3. Loosen the outlet duct clamp at the upper intake manifold cover.
  4. Remove the upper intake manifold cover from the outlet duct.
  5. Remove the upper intake manifold cover.
  6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.

    8. Object Number: 652573 Size: SH
  8. Reposition the air conditioning (A/C) compressor using the following procedure:
    9. 8.1. Disconnect the A/C compressor clutch electrical connector.
    8.2. Disconnect the A/C cut out switch electrical connector.
    8.3. Remove the A/C compressor mounting bolts.
    8.4. Reposition the A/C compressor with the hoses attached to the right side of the engine compartment.

    Object Number: 759733 Size: SH
  9. Disconnect the left front injector harness electrical connector (1).
  10. Disconnect the oil pressure sending unit electrical connector.

    11. Object Number: 668427 Size: SH
  11. Disconnect the turbocharger coolant hose and clamp from the turbocharger bypass valve.

    12. Object Number: 699329 Size: SH
  12. Disconnect the water outlet tube using the following procedure:
    13. 12.1. Remove the bolts attaching the water outlet tube to the left rocker arm cover.
    12.2. Remove the bolt attaching the water outlet tube to the thermostat housing.
    12.3. Remove the water outlet tube.
    12.4. Remove and discard the O-ring seal.

    Object Number: 687021 Size: SH
  13. Reposition the positive crankcase ventilation (PCV) hose clamp.
  14. Remove the PCV hose from the upper valve rocker arm cover.

    15. Object Number: 877281 Size: SH
  15. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

    16. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  16. Remove the charged air cooler inlet duct from the turbocharger.

    17. Object Number: 755766 Size: SH
  17. Remove the banjo bolt (1) from the fuel junction block.
  18. Disconnect the fuel pipes (3) from the fuel junction block.

    19. Object Number: 755759 Size: SH
  19. Disconnect the fuel pipe junction block from the fuel rail (1).

    20. Object Number: 660442 Size: SH
  20. Remove the fuel junction block nuts.
  21. Remove the fuel junction block.

Installation Procedure

    Object Number: 755766 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the fuel junction block and nuts.

    2. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

  2. Install the fuel pipe junction block to the fuel rail (1).

    3. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

  3. Connect the fuel pipes (3) to the junction block.

    4. Tighten
    Tighten the fittings to 44 N·m (32 lb ft).


    Object Number: 755759 Size: SH
  4. Connect the fuel pipe junction block to the fuel rail (1).

    5. Tighten
    Tighten the fitting to 44 N·m (32 lb ft).


    Object Number: 877281 Size: SH
  5. Install the charged air cooler inlet duct to the turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance.

    8. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 687021 Size: SH
  8. Install the PCV hose to the upper valve rocker arm cover.
  9. Reposition the PCV hose clamp.

    10. Object Number: 699329 Size: SH
  10. Install the water outlet tube using the following procedure:
    11. 10.1. Install a new O-ring seal on the water outlet tube.
    10.2. Lightly lubricate the O-ring seal with coolant.
    10.3. Install the water outlet tube.
    10.4. Install the bolt attaching the water outlet tube to the thermostat housing.

    Tighten
    Tighten the bolt to 21 N·m (16 lb ft).

    10.5. Install the bolts attaching the water outlet tube to the rocker arm cover.

    Tighten
    Tighten the bolts to 21 N·m (16 lb ft).


    Object Number: 668427 Size: SH
  11. Install the turbocharger coolant hose and clamp to the turbocharger bypass valve.
  12. Connect the oil pressure sending unit electrical connector.

    13. Object Number: 759733 Size: SH
  13. Connect the left front injector harness electrical connector (1).

    14. Object Number: 652573 Size: SH
  14. Install the A/C compressor using the following procedure:
    15. 14.1. Install the A/C compressor bolts.

    Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

    14.2. Connect the A/C cut out switch electrical connector.
    14.3. Connect the A/C compressor clutch electrical connector.
  15. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  16. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    17. Object Number: 813243 Size: SH
  17. Install the upper intake manifold cover.
  18. Install the upper intake manifold cover to the outlet duct.
  19. Tighten the outlet duct clamp at the upper intake manifold cover.

    20. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    21. Object Number: 310799 Size: SH
  21. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1).

    22. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  22. Purge air from the fuel system.